Medical bandage substrate, medical bandage, and medical bandaging product with low abrasion side edges, and method

ABSTRACT

A medical bandaging product, including a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture, and a medical material positioned in the sleeve and sealed therein against entry of moisture until use. The medical material is a substrate having two marginal areas of relatively lower modulus yarns and/or a more open knitted structure to provide reduced abrasion against the skin. A reactive system on the substrate remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a rigid, self supporting structure. A soft, flexible protective material covers at least one of the major faces of the substrate along its length to provide a cushioning barrier between the substrate and the skin of a patient when the material is in use.

CROSS REFERENCE TO RELATED APPLICATIONS

This continuation patent application claims the benefit of, priority of,and incorporates by reference herein, U.S. national stage patentapplication Ser. No. 11/816,635, filed Aug. 26, 2008, which claimspriority to PCT application number PCT/US2006/003796, filed on Feb. 3,2006, which claims priority to PCT application number PCT/US05/009041,filed Mar. 17, 2005, which claims priority to U.S. provisionalapplication No. 60/654,172, filed on Feb. 18, 2005, entitled “MedicalBandage Substrate, Medical Bandage, and Medical Bandaging Product andMethod.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates generally to the field of orthopedicmedicine and more specifically to the design of an improved medicalbandage substrate, a medical bandage formed of a moisture-curablematerial, particularly a splint, and a medical bandaging product. Thepresent invention also relates to a method of forming a medical bandagesubstrate.

Medical bandages for use in the treatment of injuries, such as brokenbones requiring immobilization of a body member, are generally formedfrom a strip of fabric or scrim material impregnated with a substancewhich hardens into a rigid structure after the strip has been wrappedaround the body member. The hardening substance traditionally used incarrying out this procedure is plaster-of-paris.

Conventional practice has been to fabricate a cast or splint upon aninjured limb by initially applying to the limb a protective covering ofa cotton fabric or the like and then overwrapping the covering and limbwith a woven cloth impregnated with plaster-of-paris which has beenwetted by dipping in water immediately prior to application. Thispractice is still in widespread use but possesses several significantdisadvantages. For example, the above-described application procedure ismessy and time-consuming. Several components are required andconsiderable skill is necessary. The hardened material is subject todeterioration during wear, and can cause odor and itching.

In order to alleviate the above-recited disadvantages of theconventional application procedure for plaster-of-paris casts andsplints, unitary splinting materials have been devised and are disclosedin, for example, U.S. Pat. Nos. 3,900,024, 3,923,049, and 4,235,228. Allof these patents describe a padding material with a plurality of layersof plaster-of-paris impregnated cloth. Such unitary splinting materialsare not as messy and can be applied more quickly but still suffer from anumber of disadvantages inherent in plaster-of-paris cast materials. Allplaster-of-paris splints have a relatively low strength to weight ratiowhich results in a finished splint which is very heavy and bulky.Plaster-of-paris splints are slow to harden, requiring 24 to 72 hours toreach maximum strength. Since plaster-of-paris breaks down in water,bathing and showering are difficult.

An advance in the art of casting and splinting is disclosed in U.S. Pat.Nos. 4,411,262 and 4,502,479. The casting materials disclosed in thesepatents comprise a flexible fabric impregnated with a moisture-curingresin enclosed in a moisture-free, moisture-impervious package. Comparedto plaster-of-paris, these products are extremely lightweight, have avery high strength to weight ratio and can be made relatively porous,permitting a flow of air through the splinting material. Prior artmoisture-curing systems include a package within which is contained aplurality of layers of fabric, such as fiberglass, impregnated with amoisture-curing resin. No provision is made for re-closing the package,so that the entire material must be very quickly used after removal fromthe package since such moisture-curing resins will cure in a relativelyshort period of time due merely to contact with atmospheric moisture.

Further significant developments in the splinting area are disclosed inU.S. Pat. Nos. 4,770,299; 4,869,046; 4,899,738 and 5,003,970, owned bythe present applicant. Each of these patents discloses variousroll-form, moisture-curable splint products that permit predeterminedlengths of a medical bandage to be severed from a roll for use, whilethe remaining medical bandage is maintained in a soft, moisture-proofcondition until ready for later use. These applications disclose the useof multiple layers of fiberglass fabric positioned in a synthetic,non-woven fabric protective layer for residing between the hardenedsubstrate and the patient.

The present application presents and discloses further improvementsaddressed to presently-used products.

In particular, a substrate is disclosed having side edges of thesubstrate of formed in such a way as to be less rigid when cured,thereby improving comfort to the patient. The substrate is more formableand the lamination will not separate when wrapping around an angle, forexample, heel or elbow.

The invention described in this application combine the advantages ofboth plaster-of-paris and moisture-curable resin systems while avoidingtheir respective disadvantages. This is accomplished by providingunitary splinting systems with improved strength and convenience. Onesuch unitary system uses a moisture-curing resin together with amoisture-impervious package with means for resealing the package againstentry of moisture after a desired length of bandaging product has beenremoved for use. In this manner, hardening of the bandaging productremaining in the moisture-impervious package is prevented therebyincreasing the cost effectiveness of the system substantially. Anotherunitary system provides pre-cut lengths sealed against moistureintrusion until use.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a medical bandagesubstrate with improved use characteristics.

It is another object of the invention to provide a medical bandage thathas side edges with improved flexibility and conformability.

It is another object of the invention to provide a medical bandageproduct in roll form with a moisture-curable resin which hardens thematerial upon exposure to moisture to form a rigid, self-supportingstructure.

It is another object of the invention to provide a medical bandagingproduct which can be dispensed in any desired length while preventinghardening of the remaining material until use is desired.

It is another object of the invention to provide a medical bandageproduct in pre-cut lengths with a moisture-curable resin which hardensthe material upon exposure to moisture to form a rigid, self-supportingstructure.

It is another object of the invention to provide a medical bandageproduct.

It is another object of the invention to provide a unitary medicalbandaging product which includes a soft, protecting wrapping to providea cushion against the skin of a patient.

It is another object of the invention to provide a medical bandagesubstrate that can be incorporated into a soft, protecting wrappingafter removal from its storage container and before application to thepatient.

It is another object of the invention to provide a method ofconstructing a medical substrate having the characteristics and objectsdescribed above.

It is another object of the invention to provide a method of applying amedical bandage having the characteristics and objects described above.

These and other objects of the present invention are achieved in thepreferred embodiments disclosed below by providing a substrate for amedical bandage, comprising an elongate fabric having two opposed majorfaces connected by yarns extending between the faces. The yarns have apredetermined, relatively high modulus sufficient to provide rigidity tothe fabric when conformed to an injury site and hardened by activationof a reactive system applied to the fabric. Two opposed, relativelynarrow and longitudinally-extending side marginal areas are formed onthe fabric and define two opposed side edges. The marginal areas areformed to provide a sufficient degree of softness and flexibility whenconformed to an injury site and are hardened by activation of a reactivesystem applied to the marginal areas of the fabric to thereby reduceabrasion between the marginal areas of the substrate and the injurysite.

According to one preferred embodiment of the invention, the marginalareas are formed at least partially of yarns having a predetermined,relatively low modulus.

According to another preferred embodiment of the invention, the fabricand the marginal areas comprises a warp knitted double fabric, and themarginal areas are formed at least partially of low modulus yarns areselected from the group consisting of polyester, polyethylene andpolypropylene.

According to yet another preferred embodiment of the invention, themarginal areas are formed of low modulus yarns selected from the groupconsisting of polyester, polyethylene and polypropylene, and have atransverse extent of between about 1 to 15 wales.

According to yet another preferred embodiment of the invention, themarginal areas have a transverse extent of between about 4 to 7 wales.

According to yet another preferred embodiment of the invention, themarginal areas are knitted and comprise a more open knitted structure inrelation to the knitted structure of the fabric.

According to yet another preferred embodiment of the invention, thefabric comprises a warp knitted double fabric constructed from yarnsselected from the group consisting of glass, high tenacity polyester,polypropylene, aramid, and ultra high molecular weight polyethylene.

According to yet another preferred embodiment of the invention, the yarncount range is between about 20 Tex and about 136 Tex.

According to yet another preferred embodiment of the invention, the yarncount range is between about 44 Tex and about 136 Tex.

According to yet another preferred embodiment of the invention, whereinthe fabric that forms the substrate comprises about 450-580 courses permeter and about 15-25 wales per 10 centimeters.

According to yet another preferred embodiment of the invention, thefabric thickness ranges from 1 mm to 10 mm.

According to yet another preferred embodiment of the invention, thefabric has a weight of about 500 to about 3000 grams per square meter.

According to yet another preferred embodiment of the invention, thefabric comprises a warp knitted fabric, and further comprises aplurality of ingress channels formed by wales omitted at intervals alongthe length of the substrate.

According to yet another preferred embodiment of the invention, asubstrate for a medical bandage comprises an elongate fabric having twoopposed major faces connected by yarns extending between the faces. Theyarns have a predetermined, relatively high modulus sufficient toprovide rigidity to the fabric when conformed to an injury site andhardened by activation of a reactive system applied to the fabric. Twoopposed, relatively narrow and longitudinally-extending side marginalareas are formed on the fabric and defining two opposed side edges. Themarginal areas are formed to provide a sufficient degree of softness andflexibility when conformed to an injury site and hardened by activationof a reactive system applied to the marginal areas of the fabric tothereby reduce abrasion between the marginal areas of the substrate andthe injury site. The marginal areas comprise a knitted constructionhaving an open knitted structure in relation to the knitted structure ofthe fabric.

According to yet another preferred embodiment of the invention, amedical bandage is provided and comprises an elongate fabric having twoopposed major faces connected by yarns extending between the faces, theyarns having a predetermined, relatively high modulus sufficient toprovide rigidity to the fabric when conformed to an injury site andhardened by activation of a reactive system applied to the fabric. Twoopposed relatively narrow and longitudinally-extending side marginalareas are formed on the fabric and defining two opposed side edges, themarginal areas being formed to provide a sufficient degree of softnessand flexibility when conformed to an injury site and hardened byactivation of a reactive system applied to the marginal areas of thefabric to thereby reduce abrasion between the marginal areas of thesubstrate and the injury site. A reactive system is applied to and intothe thickness of the substrate, the reactive system having a first statewherein the substrate remains in a flexible, conformable condition and asecond state wherein the reactive system hardens, simultaneouslyhardening the substrate into a desired conformation.

According to yet another preferred embodiment of the invention, thereactive system comprises a moisture-curable resin, and the liquidingress channels are adapted to facilitate uniform distribution of wateronto and through the thickness of the substrate.

According to yet another preferred embodiment of the invention, thefabric comprises a warp knitted double fabric constructed from yarnsselected from the group consisting of glass, high tenacity polyester,polypropylene, aramid, and ultra high molecular weight polyethylene, andincluding a moisture-curable reactive system applied to and into thethickness of the substrate, and wherein the liquid ingress channels areadapted to facilitate uniform distribution of water onto and through thethickness of the fabric.

According to yet another preferred embodiment of the invention, whereina soft, flexible protective material covers at least one of the majorfaces of the substrate and is adapted to pass water therethrough andonto the substrate.

According to yet another preferred embodiment of the invention, thesubstrate is in a precut length suitable for a particular medical use.

According to yet another preferred embodiment of the invention, thesubstrate is in the form of a roll from which desired lengths may be cutas needed.

According to yet another preferred embodiment of the invention, amedical bandaging product is provided, comprising a sleeve formed ofmoisture-impervious material and sealable to prevent entry of moisture.A medical material is positioned in the sleeve and sealed thereinagainst entry of moisture until use. The medical material comprises anelongate fabric having two opposed major faces connected by yarnsextending between the faces. The yarns have a predetermined, relativelyhigh modulus sufficient to provide rigidity to the fabric when conformedto an injury site and is hardened by activation of a reactive systemapplied to the fabric. Two opposed, relatively narrow andlongitudinally-extending side marginal areas are formed on the fabricand define two opposed side edges. The marginal areas provide asufficient degree of softness and flexibility when conformed to aninjury site and hardened by activation of a reactive system applied tothe marginal areas of the fabric to thereby reduce abrasion between themarginal areas of the substrate and the injury site. A reactive systemis impregnated into or coated onto the substrate. The system remainsstable when maintained in substantially moisture-free conditions andhardens upon exposure to sufficient moisture to form a rigid, selfsupporting structure. A soft, flexible protective material covers atleast one of the major faces of the substrate along its length toprovide a cushioning barrier between the substrate and the skin of apatient when the material is in use.

According to yet another preferred embodiment of the invention, a soft,flexible protective material covers both major faces of the substrate.

According to yet another preferred embodiment of the invention, a soft,flexible protective material is wrapped around and encloses both majorfaces and the longitudinally extending side edges of the substrate.

A method of forming a medical bandage substrate includes the steps offorming an elongate fabric having two opposed major faces connected byyarns extending between the faces, the yarns having a predetermined,relatively high modulus sufficient to provide rigidity to the fabricwhen conformed to an injury site and hardened by activation of areactive system applied to the fabric, and forming two opposed,relatively narrow and longitudinally-extending side marginal areas onthe fabric defining two opposed side edges. The marginal areas areformed to provide a sufficient degree of softness and flexibility whenconformed to an injury site and hardened by activation of a reactivesystem applied to the marginal areas of the fabric to thereby reduceabrasion between the marginal areas of the substrate and the injurysite.

According to yet another preferred embodiment of the invention, the stepof forming the marginal areas comprises the step of formed the marginalareas at least of partially of yarns having a predetermined, relativelylow modulus.

According to yet another preferred embodiment of the invention, the stepof forming the fabric and the marginal areas comprises the step offorming a warp knitted double fabric, and the further step of formingthe marginal areas at least partially of low modulus yarns are selectedfrom the group consisting of polyester, polyethylene and polypropylene.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects of the invention have been set forth above. Otherobjects and advantages of the invention will appear as the descriptionof the invention proceeds when taken in conjunction with the followingdrawings, in which:

FIG. 1 is a perspective view showing a medical bandaging productaccording to one preferred embodiment of the invention being dispensedfrom a dispenser;

FIG. 2 is a perspective view with parts broken away of a cut length ofmedical bandage;

FIG. 3 is a vertical cross-section taken substantially along lines 3-3of FIG. 2;

FIG. 4 is a perspective view of a length of the medical material withthe substrate layer exposed for clarity;

FIG. 4 is a perspective view of a medical bandage substrate according toone embodiment of the invention;

FIG. 5 illustrates activation of the moisture-curable resin in themedical material by wetting;

FIG. 6 further illustrates activation of the moisture-curable resin byproviding water ingress channels in the substrate;

FIG. 7 shows excess water being removed from the medical bandage beforeapplication;

FIG. 8 shows smoothing and straightening of the medical bandage beforeapplication;

FIGS. 9 and 10 are perspective views of the medical bandage being placedon an injured limb and being secured into place by a covering wrap;

FIG. 11 is a perspective view of an alternative design of a dispensingcontainer for holding the medical bandage until ready for dispensing;

FIG. 12 is a vertical cross-section of the dispensing container shown inFIG. 11;

FIG. 13 is a perspective view of the dispenser carton into which thecontainer is positioned; and

FIG. 14 is a perspective view of a pre-cut medical bandage stored foruse in a moisture-impervious envelope until ready for use.

DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE

Referring now specifically to the drawings, a medical bandaging productaccording to the present invention is shown generally in FIG. 1 at 10.Bandaging product 10 may be sold in any convenient length, such as 24feet, and is rolled into a coil and positioned in a suitable dispenser11. Dispenser carton 11 is provided with a slot 12 at one lower cornerthrough which bandaging product 10 is dispensed.

According to one embodiment of the invention, the bandaging product 10is formed of an outer elongate sleeve 13 formed of a moisture-imperviousmaterial, for example, a laminated metal foil and plastic. Sleeve 13 isheat sealed along opposite, parallel extending sides to form an elongatetube. An elongate medical bandage 14, described in detail below, ispositioned within sleeve 13 and is maintained in substantiallymoisture-free conditions until dispensed. The medical bandage 14 isdispensed by pulling the needed amount of material, along with thesleeve 13 in which it is enclosed, out of the carton 11 and severing itwith, for example, scissors. The remaining, raw end of the bandage 14 istucked back into the remaining sleeve 13 with a sufficient length ofsleeve available to receive a clip, such as a bar clip. Of course, anysuitable form of closure may be used so long as a seal sufficient toprevent moisture intrusion is formed.

Referring now to FIG. 2, since the appropriate length of bandage 14 isbest determined by measurement, measurement marks “M” are printed on oneedge of the sleeve 13. The sleeve 13 is preferably closely conforming tothe bandage 14 along its length in order to reduce the amount of airthat is introduced into the sleeve while it is open.

Referring now to FIGS. 3 and 4, bandage 14 comprises a substrate 16preferably formed of a double fabric of a material, which may be woven,knitted or formed according to other processes, as described in furtherdetail below. According to one embodiment of the invention the substrate16 is contained within a tubular wrapping 18 that is preferably formedof a soft, flexible non-woven fiber such as polypropylene or some othersuitable fiber. This provides a cushioning protective layer between theskin of the patient and substrate 16.

The wrapping 18 may also be selected from a wide range of othermaterials such as open cell or reticulated foam, closed cell foam, softflexible films and nonwoven materials. In the preferred form the splintis wrapped in a nonwoven material.

Alternatively, the substrate 16 may be packed in the sleeve 13 andenclosed within a protective cushioning layer just before application.This may be accomplished by folding a length of cushioning materialaround the substrate 16 and securing it in place with, for example, tapeor another form of adhesive.

Substrate 16 is impregnated or coated with a reactive system whichremains stable when maintained in substantially moisture-free conditionsbut which hardens upon exposure to sufficient moisture to form a rigid,self-supporting structure. Two typical formulations of the reactionsystem is set forth in the following table.

TABLE 1 Isonate ↓ 143L or polyisocyanate 50.0% Mondur ↓ CD or Rubinate ↓XI168 Pluracol ↓ P1010 polyol 46.6% DC-200 Silicone defoaming agent0.30% Benzoyl Chloride stabilizer 0.10% Thancat. DM-70 catalyst  3.0% 100%

TABLE 2 Isonate 143L or Polysiocyanate 50.0%  Mondur CD or Carbowax PEG600 Carbowax PEG 4600 22.0%  Carbowax PEG 8000 Voranol 230-238 Voranol220-110 18.0%  Irganox 1010 2.0% Antifoam 1400 4.0% Methane SulphonicAcid 1.0% DMDEE 3.0% 100% 

These formulations and their varying proportions are well-known.

By continued reference to FIG. 4, the substrate 16 according to oneembodiment is formed of a single layer of a knitted double fabricimpregnated with a resin, for example, one of the moisture-curableresins identified above, but also may utilize a wide range of availablepolymer chemistries, including but not limited to polyurethanes,polyureas, polyesters, polyacrylates and epoxy. In one of the preferredembodiments the splint comprises a warp knitted double fabricimpregnated with a moisture curable polyurethane resin. The warp knitteddouble fabric can be constructed using any suitable organic or inorganicyarns/fibers such as glass, high tenacity polyester, polypropylene,aramid fibers (Kevlar®) and ultra high molecular weight polyethylene(Spectra®). The yarn count ranges are preferably between 20 Tex to 136Tex and preferably 44 Tex to 136 Tex. The warp knitted double fabricformed a three-dimensional substrate 16 having a top and a bottom layerthat are interconnected using plurality of yarns. The yarns used forforming the top layer, bottom layer and the interconnection between themcan be constructed from same or different materials.

In one of the preferred embodiments, the substrate material is knittedon a double bed warp knitted machine with six guide bars. The preferredfabric notation is an inlay with a chain stitch on the surface and a“V,” butterfly or atlas stitch in the center. The yarns are knitted intoa three-dimensional fabric substrate having sufficient weight, thicknessand surface area to keep the resin within the substrate.

The fabric structure can be tailored for any level of course and walesdensity. However, in the preferred construction, the fabric that formsthe substrate 16 comprises 450-580 courses per meter, with a preferredrange of 500-550 courses per meter and 19 wales per 10 centimeters, witha preferred range of 15-25 wales per 10 centimeters. The fabric can beconstructed into any suitable width for varying limb sizes and shapes.The most preferred knitted fabric widths vary in the range of 2.5centimeters to 60 centimeters. The fabric thickness is an importantfeature as it effects the final rigidity and is also importantaesthetically for patient's comfort and ease of use. The warp knittedfabric in this embodiment can vary in thickness range from 1 mm to 10 mmand preferably in the range of 2 mm to 5 mm. The final fabric weightwill depend on various factors such as fabric construction, yarns usedand other factors that are well known in the prior art. In the mostpreferred structure the fabric weight will vary in the range of 500 to3000 grams per square meter and even more preferably in the range of1000 to 1800 grams per square meter.

According to one preferred embodiment of the invention, fiberglass yarnsare used to construct the single layer fabric. Fiberglass possessescertain advantages because of its low cost and the experience developedover years of use in conventional fiberglass splints. It has beenlearned that particular advantages result when a substrate fabric havingthe channels 20 is heat treated after knitting and before application ofthe moisture-curable resin.

In particular, heating the knitted substrate 16 incrementally to arelatively high temperature over a period of hours sufficient to burnoff processing starch and then reducing the temperature over a period ofhours to ambient temperature enables the resin to more securely andevenly coat the fiberglass filaments.

In one preferred process, the knitted fiberglass substrate is treated byslowly heating in stages to 400° C. over a period of hours, holding thetemperature at 400° C. for 6 hours, and gradually reducing thetemperature in stages to ambient temperature, the total processing timebeing approximately 24 hours. The improved resin adherence results fromthe removal of the starch coating from the surface of the fiberglassyarns, allowing the more efficient dispersion of the resin throughoutthe glass knitted structure.

However, it has also been observed unexpectedly that water penetrationinto the substrate 16 is also enhanced by heat treating as describedabove. This is believed to also be the result of the removal of thestarch layer, which may total approximately 3 percent of the totalproduct volume. Removal of the starch layer reduces the diameter of theindividual yarns, thereby increasing the open space between adjacentyarns. The cumulative effect is to increase by approximately 3 percentthe volume of the openings in the substrate 16, thereby increasing thearea available for resin penetration and, ultimately water ingress forthe purpose of curing, not only in the channels 20 but throughout thelength, width and thickness of the substrate 16.

The resulting improvement in performance has been demonstrated intesting heat treated knitted substrate material and comparable non-heattreated substrate material. In one such test, resin was applied tonon-heat treated knitted fiberglass substrate material at a ratesufficient to achieve a 36 percent resin content. The resin wasactivated by water and the strength of the substrate observed atsubsequent time intervals. Strength, observed as the kilograms of forcerequired to deform the substrate one centimeter according to a standardtest, was >1.29 after 15 minutes and >1.82 after 30 minutes. The greatervalue after 30 minutes reflects continued hardening between 15 and 30minutes, thereby requiring greater force to achieve the required onecentimeter deformation.

In contrast, resin was applied to the same knitted fiberglass substratematerial after heat treatment to remove the starch coating. As with thenon-heat treated material, the resin was applied at a rate sufficient toachieve a 36 percent resin content. The resin was activated by water andstrength of the substrate observed at subsequent time intervals.Strength, observed as the kilograms of force required to deform thesubstrate one centimeter according to a standard test, was >2.29 after15 minutes and >2.08 after 30 minutes. The greater value after 15minutes reflects a more rapid hardening in the first 15 minutes, ahighly desirable result. The overall hardness after 15 and 30 minutes isconsidered to be generally the same. As shown, the strength of the heattreated substrate is greater in both absolute terms and in the speedwith which hardening occurs than with non-heat treated substrate.

Testing also revealed that the strength of the heat treated substrateincreased at 24 hours to 3.31, or over 50 percent greater that therequired minimum strength of greater than 2.0.

As is shown in FIGS. 5-8, the bandage 14 is typically activated byspraying or pouring water on one surface of the bandage 14, FIGS. 5 and6, wringing out the excess water, FIG. 7, and smoothing the bandagebefore application, FIG. 8.

It is desirable that the bandage 14 activates and attains rigiditysufficient to hold the fracture in position as fast as possible. One ofthe factors influencing the rate of rigidification is the openness ofthe substrate structure to allow water to penetrate through thethickness of the bandage—both the wrapping 18 and the substrate 16—andactivation of the whole bandage 14 evenly and rapidly. In one preferredembodiment the substrate 16 is knitted in according to a method by whicha wale is omitted from the knitted structure at a regular interval alongthe length of the substrate 16 in either the chain, inlay or centerstitch. In the most preferred embodiment a wale end is omitted every2-10 wales. The missing wale ends create water ingress channels 20 thatextend along the length and into the thickness of the substrate 16, thusallowing for faster and more even penetration of water into thestructure of the substrate 16, as is shown schematically in FIG. 6. Theactual configuration of the channels 20 is a function of the type offabric formation technique utilized, and will generally comprise voidareas, the shape and size of which is defined by surrounding yarns orfibers. The omission of the wale ends also creates a less densesubstrate 16. This is desirable in that raw material and weight arereduced, at least to some degree. Alternative methods for creating thewater ingress channels include omitting stitches or yarns in the widthdirection of the substrate, or diagonally across and along thesubstrate, the principal point being to provide greater opportunity forwater ingress into the structure of the substrate, rather than any oneparticular method of doing so.

In accordance with another embodiment of the invention, the “V” stitchshould preferably be formed using a textured, filamented or fibrillatedyarn that improves the density of the center portion of the doublefabric, thereby improving the resin-retaining capacity of the material.

This aspect of performance enhances long term use or storage life of theproduct, avoiding the resin leaching or bleeding out of the doublefabric into the padding layer so making the product unfit for use.

In accordance with another embodiment of the invention, substrate 16 isformed with soft longitudinally extending side edges 22, 24.

As is also shown particularly in FIGS. 4 and 6, the soft marginal sideedge areas 22, 24 are created by introducing a softer, low modulus yarnsuch as polyester, polyethylene and polypropylene at the edges of thesubstrate 16. These marginal side edge areas 22, 24 may be formed of 1to 15 wales, preferably 7 wales per inch and even more preferably 4wales. In addition, a more open knitted structure may be incorporatedinto the side edges 22, 24 to further reduce the stiffness of thesubstrate 16 in these marginal areas.

Referring now to FIG. 9, an appropriate length of material 14 is formedto the shape of the body member to be immobilized. This particular typeof splint, known as a posterior short leg splint, is formed by molding alength of the product 14 to the calf and up over the heel and onto thefoot. Then, product 14 is overwrapped with an elastic conventionalbandage “B”, as is shown in FIG. 10.

Referring now to FIGS. 11-13, a medical bandaging product according toanother embodiment of the invention is shown at broad reference numeral30. The medical bandage 14 is positioned within a container 31 which isformed of two laminated elongate sheets placed in registration and heatsealed along a common seam to form a moisture proof container of thesame material and construction as the sleeve 13. The outer layer isformed of a tear-resistant plastic film and the middle layer comprisesaluminum foil and acts as a moisture barrier. The inner layer is aplastic film having thermoplastic properties suitable for heat sealingthe interior of container 31 securely against moisture.

As is also shown in FIG. 11, container 31 includes an enlarged productstorage package 34 in which is contained a coil of the medical bandage14. Package 34 is integral and communicates with an elongate dispensingsleeve 36 having an openable end 37 through which the medical bandage 14in the container 31 is dispensed.

As is shown in FIGS. 12 and 13, the end 37 of dispensing sleeve 32 maybe sealed with a clamp of any suitable type, such as a bar clamp 39, orany other suitable closure.

As is shown in FIG. 12, dispensing sleeve 36 fits snugly around themedical material 14 in order to limit exposure of the medical material14 to air which enters when the opening 37 is unsealed for dispensingthe medical bandage 14. FIG. 14 also shows that the medical material 14is coiled into a relatively tight coil to limit exposure to air andsealed into the container 31. When opening 37 is properly sealed,container 31 is sufficiently airtight so that medical material 14remains in its soft, uncured state for much longer than the usual lengthof time needed to exhaust the supply of medical material 14 in container31. If a short length of the medical material 14 adjacent the opening 37hardens, it can be cut away and discarded.

A desired length of medical material 14 is dispensed by removing clamp39 and grasping the exposed end of the medical material 14. Theappropriate length is pulled out of container 31—the medical material 14uncoiling in the storage package 34. When the proper length has beendispensed through opening 37, it is cut and the end is tucked back intothe dispensing sleeve 36. The open end 37 is quickly resealed.

As is shown in FIG. 13, if desired, the medical bandaging product 30 canbe placed inside a dispensing carton 11, with the dispensing sleeve 32of container 31 projecting out of the slot 12 in the bottom of carton11.

Referring now to FIG. 14, a pre-cut embodiment of a medical bandageproduct 40 is shown. The medical bandage product 40 comprises amoisture-impervious envelope 41 in which is packaged a pre-cut length ofthe medical bandage 14, preferably having the structure andcharacteristics described above with reference to FIGS. 1-13. Themedical bandaging product 40 is sized according to the desired end useand is labeled as such. The medical bandage 14 may be removed from theenvelope 41 and used as is, or cut and shaped as needed to meet themedical requirements of the treating physician and technician.

1. A substrate for a medical bandage, comprising: (a) an elongate fabrichaving two opposed major faces connected by yarns extending between thefaces, and two opposed, longitudinally-extending side edges defining apredetermined fabric thickness; (b) a plurality oflongitudinally-extending water ingress channels formed in the fabric andcommunicating with both of the two opposed major faces for permittingwater penetration through the fabric thickness from one of the majorfaces to the other major face.
 2. A substrate according to claim 1,wherein the fabric comprises a warp knitted double fabric.
 3. Asubstrate according to claim 1, wherein the fabric comprises a warpknitted double fabric constructed from yarns selected from the groupconsisting of glass, high tenacity polyester, polypropylene, aramid, andultra high molecular weight polyethylene.
 4. A substrate according toclaim 3, wherein the yarn count range is between about 20 Tex and about136 Tex.
 5. A substrate according to claim 3, wherein the yarn countrange is between about 44 Tex and about 136 Tex.
 6. A substrateaccording to claim 3, wherein the fabric that forms the substratecomprises about 450-580 courses per meter and about 15-25 wales per 10centimeters.
 7. A substrate according to claim 1, wherein the fabricthickness ranges from mm to 10 mm.
 8. A substrate according to claim 1,wherein the fabric has a weight of about 500 to about 3000 grams persquare meter.
 9. A substrate according to claim 1, wherein the fabriccomprises a warp knitted fabric, and further wherein the ingresschannels are formed by wales omitted at intervals along the length ofthe substrate in one or more of a chain, inlay and center stitch of thefabric.
 10. A substrate according to claim 1, wherein one wale end isomitted at the interval of between about 2-10 wales.
 11. A medicalbandage, comprising: (a) a substrate comprised of an elongate fabrichaving two opposed major faces connected by yarns extending between thefaces, and two opposed, longitudinally-extending side edges defining apredetermined fabric thickness; (b) a plurality oflongitudinally-extending liquid ingress channels formed in the fabricand communicating with both of the two opposed major faces forpermitting water penetration through the fabric thickness from one ofthe major faces to the other major face; and (c) a reactive systemapplied to and into the thickness of the substrate, the reactive systemhaving a first state wherein the substrate remains in a flexible,conformable condition and a second state wherein the reactive systemhardens, simultaneously hardening the substrate into a desiredconformation.
 12. A medical bandage according to claim 11, wherein thereactive system comprises a moisture-curable resin, and wherein theliquid ingress channels are adapted to facilitate uniform distributionof water onto and through the thickness of the substrate.
 13. A medicalbandage according to claim 11, wherein the fabric comprises a warpknitted double fabric constructed from yarns selected from the groupconsisting of glass, high tenacity polyester, polypropylene, aramid, andultra high molecular weight polyethylene, and including amoisture-curable reactive system applied to and into the thickness ofthe substrate, and wherein the liquid ingress channels are adapted tofacilitate uniform distribution of water onto and through the thicknessof the fabric.
 14. A medical bandage according to claim 11, andincluding a soft, flexible protective material covering at least one ofthe major faces of the substrate and adapted to pass water therethroughand onto the substrate.
 15. A medical bandage according to claim 11,wherein the fabric is selected from the group consisting of woven,nonwoven and knitted.
 16. A medical bandage according to claim 11,wherein the fabric thickness ranges from 1 mm to 10 mm.
 17. A medicalbandage according to claim 11, wherein the substrate is in a precutlength suitable for a particular medical use.
 18. A medical bandageaccording to claim 1, wherein the substrate is in the form of a rollfrom which desired lengths may be cut as needed.